total quality managemnt - tqm
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8/11/2019 Total quality managemnt - TQM
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7 Wastes
TOTAL QUALITY MANAGEMENT
7 Wastes
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Howoftenhaveyouusedtheexpressions:
“Thatwasawasteoftime!”
or
“Thatwasawasteofmoney!”
or
“Thatwasawasteofeffort!”
Waste
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asted Time
Justimagineifwecouldcollect
allthetime
togetherthatwehavewastedin
thepast-
Howmuchtimewouldthatbe?
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asted Money
Justimagineifwecouldcollect
allthemoney
togetherthatwehavewastedin
thepast-
Howmuchmoneywould
thatbe?
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asted Effort
Justimagineifwecouldcollect
alltheeffort
togetherthatwehavewastedin
thepast-
Howmucheffortwouldthatbe?
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he Problem With Waste
Theproblemwithwastedtime,money&effortis:
Whenit’sgone…
-it’sgone!
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liminating Waste
Sowhatcanwedotoeliminatewaste?
Wefirstneedtoidentifywhatis&isnotwaste,thenwecanlookatwaysofeliminatingoratleastreducingwaste.
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dentifying Waste in the Workplace
OperationalActivity
Value addedOperations
Anyprocessthatchangesthenature,
shapeorcharacteristicoftheproductin
linewithcustomerrequirements
e.g.Pressing,welding,heattreatment.
Thisiswherewemakeaprofit!
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dentifying Waste in the Workplace
OperationalActivity
Non Value addedOperations
Workcarriedoutwhichisnecessaryunder
currentconditions,butdoesnotincrease
productvalue.
e.g.Inspection,toolchange,maintenance.
Thisiswherewemakealoss!
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Value Added and
Non Value Added operations
TheobjectiveistoraisetheratioofValueaddedoperationstonon-valueadded
operationsandeliminatewaste.
WASTE NON-VALUE ADDED VALUE
ADDED
OPERATOR TIME
VALUE
ADDED
NON-VALUE
ADDED
MORE TIME FOR
OTHER ACTIVITIES
ELIMINATE
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W The Elimination of Waste
So,nowweunderstandthedifferenceinvalueadded&non-valueadded
operations,whatarethebenefitsin
eliminatingallwaste?
• Reducedcosts
• GreaterCapacity
• Bottlenecksareidentified
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W 7 Types of Waste
1Over-production
2Inventory
3Transportation
4Process
5IdleTime
6OperatorMotion
7BadQuality
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W 1. Over production
Over-production
Producingmorethanisneededhidesa
multitudeofproblems.Excessiveset-uptimes,
machinefaults,riskofproducingobsoletestock.
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W 2. Inventory
Inventory
Carryingstockattractscost&storage
problems.Storageleadstostacking,racking,
sophisticatedcomputers,barcoding&automation,allforanactivitythataddsno
valuetotheproduct.
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W 3. Transportation
Transportation
Thismayappearunnecessarybutdoesadd
value.Largetransportiseasilyidentifiedbut
smalltransportsuchasmanuallabourmaynotbesonoticeable.Thesecanbeimprovedby
changestotheworkenvironment.
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W 4. Process
Process
Addscostbutnovalue-e.g.trimming&
mouldingtoalevelthatisbeyondtherequired
standardaddsextratimethatcustomersdonotwanttopayfor.
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W 5. Idle Time
IdleTime
Typically,waitingforproducts&servicesfrom
precedingoperations,waitingforworkfrom
theirpreviousset-uporwaitingforcyclestofinish,ormeetingstostart.
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W 6. Operator Motion
OperatorMotion
Typically,singlehandedoperationswhere
bothshouldbeused,stretchingunnecessarily
orawkwardlyandwalkingbetweenthings.Allofthesetaketimeorusetimepoorly,noneadd
value.
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W 7. Bad Quality
BadQuality
Rejectsarealwaysproducedbysystemsandprocedurescreatedbymanagement.If
operatorsfailitisbecausetheprocessallowed
themtofailthroughinadequatetrainingorbecausetheprocesswasnotcapableinthe
firstplace.
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W The Elimination of Waste
So,nowweunderstandthe7wastes,wecan:• Produceonlywhatisneeded;
• Carryonlyessentialstock;
• Usetransportationmorewisely;
• Produceworktothestandardrequired;
• Planourproductionprocesses;
• Putoureffortstothebestpossibleuse;
• Traintomakequalityworkeverytime!